Material separation and conveyance using tuned waves

ABSTRACT

Systems, methods and computer readable media for material separation and conveying using tuned waves are disclosed.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/187,195, entitled “Material Separation Using Tuned Waves”, and filedon Feb. 21, 2014, which claims the benefit of U.S. ProvisionalApplication No. 61/767,679, entitled “Material Separation Using TunedWaves”, and filed on Feb. 21, 2013, which is incorporated herein byreference in its entirety.

FIELD

Embodiments relate generally to material separation and, moreparticularly, to systems and methods for separating materials usingtuned waves.

BACKGROUND

In aggregate ore separation, current industry standard practices mayemploy chemically intensive processes and methods such as shaker tablesand hammers. This may be a somewhat primitive method of trying tophysically separate materials (e.g., shake out the ore). Someconventional systems may be operating within a limited range offrequency separation (via pressure disturbance through mechanical wavesgenerated by physical contact with tables and hammers). This can resultin essentially one frequency, possibly un-tuned to the objects they areattempting to separate, providing only one degree of freedom. Due tothis, the efficiency and effectiveness is diluted even further whenaggregate ore is presented in multiple mediums. Not only areconventional techniques more energy intensive than might be necessaryand may be more water intensive, but an inability to tune frequencies tovery specific ranges for most efficient separation can result insignificant loss of ore that was unable to be separated at all for use.

Embodiments were conceived in light of the above-mentioned problems andlimitations, among other things.

SUMMARY

Some implementations can include systems and methods for separation,stratification and/or conveyance of aggregate ore, in various mediums,by a technique of tuning a pressure disturbance known as mechanicalwaves. Some implementations can accomplish this without the energyintensive process of generating said waves via physical contact and alsoallows multiple degrees of freedom of the aggregate ore. This processmay be accomplished via the configuration of relatively inexpensiveexisting technologies provided in an adjustable platform, that cangenerate the frequencies that can travel through the various mediums(air, water, etc.) being employed without the need for physical contact(and may be optionally communicated via a plate).

The process can include administering a stimulus of sound wave energy toa mixture (or matrix) of heterogeneous materials, then exploiting thedifferences in the individual motive response values of material types.The stimulation control values (or parameters) can be altered to promotethe greatest differential in response values between different materialtypes, which can, in turn, determine the most effective physicalconfiguration of the process hardware, and the most feasible method forfinal mechanical separation. Differences in material types to beseparated, size to be separated, rate of separation, conveyance needs orthe like, all have notable impacts on the overall settings,configuration and physical appearance of the separation equipment andscale, but the process itself may be similar.

Process settings (or parameters) can include number of output devices,power output, frequency, amplitude, signal duration, and phase of outputsignal to each device, physical orientation of output devices, angle ofincidence of each output device to a plate, plate type/configuration(e.g., plate material, plate thickness, plate type or the like),inclination angles of two axis of the apparatus, and, in the case of wetseparation, evacuation fluid flow rate, pressure, and direction of fluidflow. The frequencies/wavelengths being generated can then be tuned tospecific ranges, based on the reactions of materials to be separated.Materials of different types may have differences in measurable responsevalues. The simulation can be modified in order to create the greatestdifferential between response values, which will determine the optimalsettings, scale, and configuration of system hardware. Differences inmaterial types, size, and rate of separation, as well as moisturecontent, will have notable impacts on the above-mentioned parameters,but the process will be similar. Process settings can include number ofoutput devices, frequency, amplitude, phase of output signal, durationof output signal, physical orientation of output devices, two axis ofinclination of plate, and in the case of wet separation, fluid flowrate, pressure, and direction of fluid flow. Some implementations mayalso include automated changes in process control points based either onelapsed time, or feedback from sensory devices. Some implementations mayinclude “pinging” the resonant frequency of the materials. The principalbehind this process is that any object when sharply struck, or in thiscase pinged, will emit its own resonant frequency. Therefore, objects ofvarying make-up may emit varying frequencies.

By pinging objects with frequencies tuned for their specific make-up,the frequency emissions of objects can now be maintained. When more thanone material type is being separated, as with aggregate ore, eachindividual material type is being continually pinged so as to cause thatmaterial to resonate at its corresponding individual resonant frequency.This can cause each material to naturally fall into its respectivebandwidth. A material, upon receipt of a concussive strike, will emit aresonant frequency, possibly unique to that material type. Materialcharacteristics (e.g., density, size, weight, surface texture, or thelike) may define or influence material measurable response values. Theseresponse values may then be used to determine the optimal values of theadministered process stimulation. For example, if a material has aresponse duration (e.g., frequency emission) of 20 milliseconds, whichis to be separated from another material with a response duration valueof 10 milliseconds, then a 50 Hz output signal would maintain a constantresponse of the first martial type, but the second material type wouldbe in an unresponsive state for 10 ms, then in a responsive state for 10ms. This causes the stratification of any aggregate ore for purposes ofclaiming or reclaiming ore materials that current industry standardmethods may have not addressed in an efficient or cost productivemanner.

The principal behind this process is that any object when sharplystruck, or in this case pinged, will emit its own resonant frequency.Therefore, objects of varying make-up may emit varying frequencies. Bypinging objects with frequencies tuned for their specific make-up, thefrequency emissions of objects can now be maintained. When more than onematerial type is being separated, as with aggregate ore, each individualmaterial type is being continually pinged so as to cause that materialto resonate at its corresponding individual resonant frequency. This cancause each material to naturally fall into its respective bandwidth.Frequency emission only represents one of many measurable responseshaving values that may change based on material properties. If theresponse value of material travel in height has a greater differencethan the frequency emissions, then this particular response value may betargeted as it would provide the largest range between differingmaterial reactions.

The relationship between materials may act as its own motivating force.For example, a contained mixture of same sized materials of differingdensities would naturally lead to the denser material settling beneaththe less dense material when exposed to vibratory motivation. However,based on process control parameters the material stratification may bereversed, if desired.

In another example, if materials of the same size are of a differentshape e.g. cubes and spheres, then the cubes may agglomerate as theirflat sides prohibit motion in one degree of freedom, so the sphereswould be ejected from the cube agglomeration, and form an agglomerationof spheres.

In yet another example, when materials are separated based on texture,rough materials may encounter more friction than smooth materials, andmay lag the smooth materials when traveling over a distance. Whenmaterials are to be separated based on size, the entire mixture itselfcan effectively serve as a dynamic screen, where materials pass betweenair gaps and result in a coarse to fine progression.

Delivering multiple frequencies at once can add multiple degrees offreedom. For example, this can be observed as stratification ofmaterials by type. Once stratified, the materials can then bemechanically separated.

Some implementations can include a system comprising a controllerprogrammed to separate materials using tuned waves, and an input deviceconfigured to measure material response to stimulation. The system canalso include an output device configured to generate tuned waves basedon one or more control signals received from the controller.

The controller can be configured to provide independent control overoutput signals to each output device. The controller can be configuredto control one or more of a frequency, an amplitude, signal phasing, andsignal duration of the one or more control signals.

The system can further include a plate configured with a two-axis ofinclination and disposed so as to communicate the tuned waves from theoutput devices. The controller can be further configured to control oneor more of fluid flow, fluid pressure, and fluid flow direction for wetmaterial separation/conveyance.

The controller can be configured to perform operations. The operationscan include providing material via a material hopper, and configuring acontroller with material separation/conveyance parameters based on oneor more components of the material. The operations can also includegenerating, at the controller, one or more modulated signals inaccordance with the parameters, each modulated signal corresponding toan output device. The operations can further include amplifying themodulated signals, and supplying the amplified modulated signals to anoutput device. The operations can also include causing the material tobe separated in response to application of the modulated signals fromthe output device via a resonator plate.

The controller can be further configured to receive a feedback signalfrom a feedback sensor and provide the feedback signal to thecontroller. The controller can be further configured to adjust, with thecontroller, the modulated signal based on the received feedback signal.

Some implementations can include a method including providing materialvia a material hopper, and configuring a controller with materialseparation/conveyance parameters based on one or more components of thematerial. The method can also include generating, at the controller, oneor more modulated signals in accordance with the parameters, eachmodulated signal corresponding to an output device. The method canfurther include amplifying the modulated signals and supplying theamplified modulated signals to an output device. The method can alsoinclude causing the material to be separated in response to applicationof the modulated signals from the output device via a resonator plate.

The method can further include receiving a feedback signal from afeedback sensor and providing the feedback signal to the controller. Themethod can also include adjusting, with the controller, the modulatedsignal based on the received feedback signal. The method can furtherinclude orienting one or more of the output devices to a predeterminedangle of incidence via a gimble corresponding to each output device.

The feedback sensor can include an ultrasonic sensor. The method canalso include moving each separated components of the material to arespective output chute.

Some implementations can include a nontransitory computer readablemedium having stored thereon instructions that, when executed by aprocessor, cause the processor to perform operations. The operations caninclude providing material via a material hopper, and configuring acontroller with material separation/conveyance parameters based on oneor more components of the material. The operations can also includegenerating, at the controller, one or more modulated signals inaccordance with the parameters, each modulated signal corresponding toan output device. The operations can further include amplifying themodulated signals, and supplying the amplified modulated signals to anoutput device. The operations can also include causing the material tobe separated in response to application of the modulated signals fromthe output device via a resonator plate.

The operations can also include receiving a feedback signal from afeedback sensor and providing the feedback signal to the controller. Theoperations can further include adjusting, with the controller, themodulated signal based on the received feedback signal. The operationscan also include orienting one or more of the output devices to apredetermined angle of incidence via a gimble corresponding to eachoutput device.

The feedback sensor can include an ultrasonic sensor. The operations canalso include moving each separated components of the material to arespective output chute.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is photograph of an example wet aggregate.

FIG. 2 is a photograph of an example dry aggregate.

FIG. 3 is a diagram of an example system for separating materials usingtuned waves in accordance with at least one embodiment.

FIG. 4 is a diagram of an example system for separating material usingtuned waves in accordance with at least one embodiment.

FIG. 5 is a diagram of an example process flow for separating materialsusing tuned waves in accordance with at least one embodiment.

FIG. 6 is a diagram of an example computer system for materialseparation and conveyance using tuned waves in accordance with at leastone embodiment.

FIG. 7 is a diagram of an example system for material separation andconveyance using tuned waves in accordance with at least one embodiment.

FIG. 8 is a diagram of an example output wave pattern for materialseparation and conveyance using tuned waves in accordance with at leastone embodiment.

FIG. 9 is a diagram of an example system for material separation andconveyance using tuned waves in accordance with at least one embodiment.

FIG. 10 is a diagram of an example system for material separation andconveyance using tuned waves in accordance with at least one embodiment.

FIGS. 11-13 are diagrams showing various views of an example system formaterial separation and conveyance using tuned waves in accordance withat least one embodiment.

DETAILED DESCRIPTION

In general, material separation using tuned waves can include energizingan aggregate material with a specific frequency or set of frequencies.The frequency can be determined by measuring a physical response of theaggregate material to output device stimulation and receiving theresponse via an electrical and/or software interface and storing thereceived response for integration into a final output profile of thetuned wave separation system.

An example frequency bandwidth can be on the order of less than or equalto about 200 Hz, for example. An actual bandwidth can also be determinedempirically based on testing of material responses.

In operation, output device (e.g., acoustical emitter) modulation isdetermined by one or more software controlled output signals inaccordance with the above-mentioned frequency response. Output devicephysical orientation can be determined by a geometric relationshipbetween the emitter and aggregate material present for separation. Forexample, outputs may be phased so that no more than 120 degrees ofseparation will exist for any one of the emitters within the physicalmachine structure. Some implementations can be used to create a vortexof sound (or tuned wave energy) in order to separate aggregate material.

FIG. 1 is photograph of an example wet aggregate 100 showing a firstmaterial portion 102 and a second material portion 104 having beenseparated using an embodiment of the system described herein. FIG. 2 isa photograph of an example dry aggregate 200 showing a first materialportion 102 and a second material portion 104 having been separatedusing an embodiment of the system described herein.

FIG. 3 is a diagram of an example system 300 for separating materialsusing tuned waves in accordance with at least one embodiment. The system300 includes a mixed material supply 302, a separator 304 including aplate and one or more tuned wave output devices, a first material chute306 and a second material chute 308.

FIG. 4 is a diagram of an example system 400 for separating materialusing tuned waves in accordance with at least one embodiment. The system400 includes a power supply 402, a human-machine interface 404, acommunications link 406 and a central processing unit 408. The system400 also includes a file storage/retrieval system 410 (e.g., database),data modulation and recipe parameter control module 412.

In operation, the processor 408 can output a modulated signal 414 to anamplifier 416. The amplified signal can be supplied to a wave generator420, which can supply an amplified output 422 to a resonator plate 424in contact with material to be separated (or conveyed) 426. The system400 can also include a feedback loop 418 for providing a feedbackchannel so that the processor can automatically adjust systemparameters.

FIG. 5 is a diagram of an example process flow 500 for separatingmaterials using tuned waves in accordance with at least one embodiment.The process 500 includes providing material to be separated or conveyed502 and subjecting the material to mechanical waves 504.

The waves are received by a receiving device 506 and used to stimulatethe material 508. The stimulated material may exhibit vibration or othermotion based on mechanical wave energy absorption, reflection anddensity of material 510. The material can be guided via a manual orautomatic guide system to collection bins 512.

FIG. 6 is a diagram of an example computing device 600 that can beconfigured for material separation and/or conveyance using tuned wavesin accordance with some implementations. The computing device 600includes a processor 602, operating system 604, memory 606 and I/Ointerface 608. The memory 606 can include a material separation and/orconveyance tuned wave application 610 and a database 612 (e.g., forstoring tuned wave parameters or the like).

In operation, the processor 602 may execute the material separationand/or conveyance tuned wave application 610 stored in the memory 606.The material separation and/or conveyance tuned wave application 610 caninclude software instructions that, when executed by the processor,cause the processor to perform operations for material separation and/orconveyance tuned wave in accordance with the present disclosure (e.g.,the material separation and/or conveyance tuned wave application 610 canperform one or more of steps 402-426 and/or 502-512 described above and,in conjunction, can access the database 612). The material separationand/or conveyance tuned wave application 610 can also operate inconjunction with the operating system 604.

FIG. 7 is a diagram of an example system for material separation andconveyance using tuned waves in accordance with at least one embodiment.The system includes a material hopper that feeds material onto aseparation table. The material can be separated into three streams asshown in FIG. 7. The system can also include adjustable height feet. Thesystem can include an ultrasonic sensor disposed on one or more materialstream guide members.

FIG. 8 is a diagram of an example output wave pattern for materialseparation and conveyance using tuned waves in accordance with at leastone embodiment. The wave pattern can include a plurality of outputdevices generating waves at different frequencies (shown as ringspacing) and power levels (shown as ring size) as shown in FIG. 8.

FIG. 9 is a diagram of an example output device placement andorientation in a system for material separation and conveyance usingtuned waves in accordance with at least one embodiment. Output Device #1(B) is shown oriented generally perpendicular to the resonator plate.Output Device #2 (C) is oriented generally perpendicular to theresonator plate and spaced a distance below the plate. Output Device #3(D) is oriented by a gimble (E) so as to have a longitudinal directionof the output wave at an angle of incidence to the resonator plate.

FIG. 10 is a diagram of an example system for material separation andconveyance using tuned waves in accordance with at least one embodiment.The system includes a material hopper (A), a fluid nozzle (B), anultrasonic sensor (C) to sense material and provide feedback to acontroller, a plate (D), and adjustable legs (E).

FIGS. 11-13 are diagrams showing various views of an example system formaterial separation and conveyance using tuned waves in accordance withat least one embodiment.

In addition to separating material, the tuned wave methods and systemsdescribed herein can be used to convey material. While examples havebeen described in terms of separating one or more materials from anaggregate material, it will be appreciated that other types of materialscan be separated and/or conveyed using tuned wave systems and methods asdescribed herein, such as waste streams (trash and/or recyclingstreams), food products, agricultural products and the like. In generalany material where a need may exist to separate constituents (or conveymaterial) may be processed using an implementation of the tuned waveseparation/conveyance techniques described herein.

It will be appreciated that the modules, processes, systems, andsections described above can be implemented in hardware, hardwareprogrammed by software, software instructions stored on a nontransitorycomputer readable medium or a combination of the above. A system asdescribed above, for example, can include a processor configured toexecute a sequence of programmed instructions stored on a nontransitorycomputer readable medium. For example, the processor can include, butnot be limited to, a personal computer or workstation or other suchcomputing system that includes a processor, microprocessor,microcontroller device, or is comprised of control logic includingintegrated circuits such as, for example, an Application SpecificIntegrated Circuit (ASIC). The instructions can be compiled from sourcecode instructions provided in accordance with a programming languagesuch as Java, C, C++, C#.net, assembly or the like. The instructions canalso comprise code and data objects provided in accordance with, forexample, the Visual Basic™ language, or another structured orobject-oriented programming language. The sequence of programmedinstructions, or programmable logic device configuration software, anddata associated therewith can be stored in a nontransitorycomputer-readable medium such as a computer memory or storage devicewhich may be any suitable memory apparatus, such as, but not limited toROM, PROM, EEPROM, RAM, flash memory, disk drive and the like.

Furthermore, the modules, processes systems, and sections can beimplemented as a single processor or as a distributed processor.Further, it should be appreciated that the steps mentioned above may beperformed on a single or distributed processor (single and/ormulti-core, or cloud computing system). Also, the processes, systemcomponents, modules, and sub-modules described in the various figures ofand for embodiments above may be distributed across multiple computersor systems or may be co-located in a single processor or system. Examplestructural embodiment alternatives suitable for implementing themodules, sections, systems, means, or processes described herein areprovided below.

The modules, processors or systems described above can be implemented asa programmed general purpose computer, an electronic device programmedwith microcode, a hard-wired analog logic circuit, software stored on acomputer-readable medium or signal, an optical computing device, anetworked system of electronic and/or optical devices, a special purposecomputing device, an integrated circuit device, a semiconductor chip,and/or a software module or object stored on a computer-readable mediumor signal, for example.

Embodiments of the method and system (or their sub-components ormodules), may be implemented on a general-purpose computer, aspecial-purpose computer, a programmed microprocessor or microcontrollerand peripheral integrated circuit element, an ASIC or other integratedcircuit, a digital signal processor, a hardwired electronic or logiccircuit such as a discrete element circuit, a programmed logic circuitsuch as a PLD, PLA, FPGA, PAL, or the like. In general, any processorcapable of implementing the functions or steps described herein can beused to implement embodiments of the method, system, or a computerprogram product (software program stored on a nontransitory computerreadable medium).

Furthermore, embodiments of the disclosed method, system, and computerprogram product (or software instructions stored on a nontransitorycomputer readable medium) may be readily implemented, fully orpartially, in software using, for example, object or object-orientedsoftware development environments that provide portable source code thatcan be used on a variety of computer platforms. Alternatively,embodiments of the disclosed method, system, and computer programproduct can be implemented partially or fully in hardware using, forexample, standard logic circuits or a VLSI design. Other hardware orsoftware can be used to implement embodiments depending on the speedand/or efficiency requirements of the systems, the particular function,and/or particular software or hardware system, microprocessor, ormicrocomputer being utilized. Embodiments of the method, system, andcomputer program product can be implemented in hardware and/or softwareusing any known or later developed systems or structures, devices and/orsoftware by those of ordinary skill in the applicable art from thefunction description provided herein and with a general basic knowledgeof the software engineering and material science arts.

Moreover, embodiments of the disclosed method, system, and computerreadable media (or computer program product) can be implemented insoftware executed on a programmed general purpose computer, a specialpurpose computer, a microprocessor, or the like.

It is, therefore, apparent that there is provided, in accordance withthe various embodiments disclosed herein, methods, systems and computerreadable media for material separation and conveyance using tuned waves.

While the disclosed subject matter has been described in conjunctionwith a number of implementations, it is evident that many alternatives,modifications and variations would be, or are, apparent to those ofordinary skill in the applicable arts. Accordingly, Applicants intend toembrace all such alternatives, modifications, equivalents and variationsthat are within the spirit and scope of the disclosed subject matter.

What is claimed is:
 1. A method comprising: providing material via amaterial hopper; configuring a controller with materialseparation/conveyance parameters based on one or more components of thematerial; generating, at the controller, one or more modulated signalsin accordance with the parameters, each modulated signal correspondingto an output device; amplifying the modulated signals; supplying theamplified modulated signals to one or more of the output devices;causing the material to be separated in response to application of themodulated signals from one or more of the output devices via a resonatorplate; and orienting one or more of the output devices to apredetermined angle of incidence via a gimble corresponding to eachoutput device.
 2. The method of claim 1, further comprising receiving afeedback signal from a feedback sensor and providing the feedback signalto the controller.
 3. The method of claim 2, further comprisingadjusting, with the controller, one or more of the modulated signalsbased on the received feedback signal.
 4. The method of claim 2, whereinthe feedback sensor is an ultrasonic sensor.
 5. The method of claim 1,further comprising moving each separated component of the material to arespective output chute.
 6. A nontransitory computer readable mediumhaving stored thereon instructions that, when executed by a processor,cause the processor to perform operations including: providing materialvia a material hopper; configuring a controller with materialseparation/conveyance parameters based on one or more components of thematerial; generating, at the controller, one or more modulated signalsin accordance with the parameters, each modulated signal correspondingto an output device; amplifying the modulated signals; supplying theamplified modulated signals to one or more of the output devices;causing the material to be separated in response to application of themodulated signals from one or more of the output devices via a resonatorplate; and orienting one or more of the output devices to apredetermined angle of incidence via a gimble corresponding to eachoutput device.
 7. The nontransitory computer readable medium of claim 6,wherein the operations further comprise receiving a feedback signal froma feedback sensor and providing the feedback signal to the controller.8. The nontransitory computer readable medium of claim 7, wherein theoperations further include adjusting, with the controller, one or moreof the modulated signals based on the received feedback signal.
 9. Thenontransitory computer readable medium of claim 7, wherein the feedbacksensor is an ultrasonic sensor.
 10. The nontransitory computer readablemedium of claim 6, wherein the operations further include moving eachseparated component of the material to a respective output chute.